JPS5929436B2 - Decorative board manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a decorative laminate, and more particularly to a method for manufacturing a synchronous embossed decorative laminate having an uneven pattern that is synchronized with a pattern.

Conventionally, there are roughly two methods for imparting unevenness that matches the pattern on the surface of a thermosetting resin decorative board.

The first method is called the direct embossing method,
Typical examples include a method in which an ebony plate that matches the pattern is used to directly create irregularities on the decorative board using a flat plate press, and a method in which an embossing roll is used to directly create irregularities on the decorative board surface.

However, with this method, it is expensive to manufacture the embossing plate and embossing roll, and it is difficult to register the design of the decorative board with the uneven pattern of the embossing plate and embossing roll, which takes time to manufacture, resulting in cost problems. It was hot. The second method is generally called the chemical embossing method, in which a pattern is formed on the base paper for resin impregnation using ink containing a resin polymerization inhibitor to create a difference in the curing speed of the resin on the surface of the decorative board. , a method of forming an embossed pattern on the surface by utilizing the difference, or a method of forming a pattern on the base paper for resin impregnation with ink containing a substance that has a repellent effect against resin, and then forming a pattern on the ink area during application or impregnation. There is a method of repelling the resin to form an embossed pattern. These methods are extremely advantageous in terms of matching the design and the embossed pattern, but in the case of the former, it takes time for the resin to harden and only the volumetric contraction of the resin is used, so it is difficult to create a depression. This naturally limits the width, making it impossible to form a recess with a deep floor of arbitrary width, and urea resin, melamine resin,
Thermosetting resins molded under heat and pressure, such as tap resins, are not very effective.

On the other hand, various experiments were conducted on the latter, but the repelling effect alone was not sufficient.
There was a problem in that a sufficient embossing effect could not be achieved with heat and pressure molding type resins. The present invention overcomes the above-mentioned drawbacks and in a relatively simple and therefore low cost manner.
Moreover, the object is to manufacture an embossed decorative board that can be applied to thermosetting resins of heat-pressing molding type.

That is, in the present invention, after providing a pattern on decorative paper with an ink containing a resin that has releasability to the thermosetting resin to be impregnated and a curing inhibitor to the thermosetting resin to be impregnated, The thermosetting resin is cured, and then the entire surface of the decorative paper including the pattern is impregnated with the thermosetting resin and dried to produce impregnated paper.Then, the impregnated paper is layered on a base material, and a molded plate or film is further placed on top of it. is placed, heat and pressure is applied to cure the thermosetting resin in the non-patterned area, and the uncured resin on the pattern is adhered onto the molded plate or film, and the molded plate or film is peeled off. The gist of the present invention is a method for manufacturing a decorative board, which is characterized by forming a recessed portion. Hereinafter, the above-mentioned present invention will be explained in detail.

First, the explanation using a principle diagram is as follows.
As shown in Fig. 1, a cloth grain pattern, a wood grain pattern, etc. are printed on the decorative paper 1 as a base pattern using a normal ink or paint composition, or a wood grain pattern, an abstract pattern, etc. is printed directly on the decorative paper 1. After applying the pattern 2 only on the areas where the coating surface is desired to be depressed using ink containing a resin that has releasability to the thermosetting resin to be impregnated and a curing inhibitor to the thermosetting resin to be impregnated. , the above-mentioned releasable resin is cured.

Next, as shown in the second figure, the printed paper is coated with or impregnated with a thermosetting resin 3, and after drying, an impregnated decorative paper is obtained.

Next, as shown in Figure 3, impregnated paper is placed on top of the base material 4 with the pattern 2 on the surface, and then a molded plate or film 5 such as a metal plate or plastic film is placed on top of the paper and heated by normal means. Apply pressure. By this heating and pressure molding, as shown in the fourth diagram, the thermosetting resin in the area other than the pattern 2 is cured, the thermosetting resin in the area of the pattern 2 remains uncured, and the cured part 6 and the uncured part 3 occurs.

This is because the hardening inhibitor contained in the pattern 2 moves to the upper part of the pattern layer. This is thought to be because the impregnated thermosetting resin on the upper part of the pattern layer is in an uncured state. Next, as shown in Figure 5, when the molded plate or film 5 is peeled off, the uncured portion 3
The resin adheres and is peeled off. The uncured portion 3 has poor affinity with the removable resin in the pattern 2, so it peels off without leaving any residue on the pattern 2, and since it is in an uncured state, it does not adhere to the molded plate or film under heat and pressure. It's in easy condition. In this way, a decorative board 1 having an uneven pattern that matches the pattern 2 is obtained. In this decorative board 1, the pattern 2 is exposed because there is no hardened layer of thermosetting resin in the recessed portion, but since the peelable resin in the pattern 2 is hardened, it is extremely durable. In the present invention, the decorative paper may be paper such as titanium paper, thin paper, or kraft paper, cloth such as cotton cloth or glass cloth, or nonwoven fabric. Furthermore, as a method for specifying base patterns such as cloth grain patterns, wood grain patterns, and patterns of areas to be recessed on these decorative papers, for example, ordinary printing methods such as letterpress printing, offset printing, gravure printing, or screen printing can be used. It can be formed by printing, drawing, or painting by a hand-drawing method, a normal painting method, or the like. Next, as the ink or coating composition for applying the base pattern in the above-mentioned present invention, known ones,
For example, colorants such as dyes or pigments are added to the ink or paint vehicle, and further additives such as plasticizers, stabilizers, waxes/greases, desiccants, auxiliary desiccants, hardeners, thickeners, dispersants, fillers, etc. By optionally adding known additives such as
An ink or coating composition prepared by sufficiently kneading a solvent, a diluent, etc. can be used.

In the above ink or coating composition, the vehicle may be a known one, such as various oils and fats such as linseed oil, soybean oil, or synthetic drying oil, or natural resins such as rosin, copal dammar, hardened rosin, rosin ester, or polymerized rosin. and synthetic resins such as processed resins, rosin-modified phenolic resins, 100% phenolic resins, maleic acid resins, alkyd resins, petroleum resins, vinyl resins, acrylic resins, polyamide resins, epoxy resins, amino alkyd resins, Cellulose derivatives such as nitrocellulose and ethylcellulose, rubber derivatives such as chlorinated rubber and cyclized rubber, as well as glue, casein, diestrin, zein, etc. can be used.

Next, among the constituent components of the ink composition used to provide the pattern formed in the recesses in the above, first, as the resin that has releasability to the thermosetting resin to be impregnated, fluorocarbon resin etc. Thermoplastic resins or thermosetting resins such as melamine resins, urea resins, silicone resins, etc. are used.

In particular, when using a reactive type resin as the thermosetting resin to be impregnated, it is preferable to use a resin that has a type of releasability different from the curing reaction of the thermosetting resin to be impregnated. For example, condensation type silicone resins or melamine resins are suitable as release resins for diallyl phthalate resins. Further, when the thermosetting resin to be impregnated is a radical polymerization type such as an unsaturated polyester resin or diallyl phthalate resin, hydroquinone, methoquinone, etc. can be used as a curing inhibitor. When a reactive type resin is used as the resin having peelability at this time, it is necessary to use a condensation type resin. In the above ink composition, the curing inhibitor is 10 to 200 wt% of the sum of the release resin and the curing inhibitor, preferably 15 to 80 wt% (Ff
) is recommended. If it is less than 10wt01), the effect of curing inhibition on the thermosetting resin to be impregnated is not sufficient, and the cohesive force between the parts affected by the inhibitor and the parts not affected by the thermosetting resin is large, and the peelable resin It is impossible to obtain an uneven shape due to insufficient affinity with the molded plate or film and the force of adhesion to the molded plate or film.
This is because if the amount exceeds 01), the curing effect of the release resin will be affected, the fastness of the ink film will become weaker, and the release from the thermosetting resin will also become worse.

The above ink composition is made by using the above two substances as the main components of the vehicle, adding coloring agents such as dyes and pigments to this, optionally adding necessary additives, and thoroughly kneading with a solvent, diluent, etc. That's what happens.

Next, in the present invention, the method of applying resin treatment to the printing paper includes, for example, a method of immersing the printing paper in a solution type or emulsion type resin liquid and drying it, or a method of applying the resin treatment to the printing paper. Coating or applying the resin liquid as above,
This can be done by a drying method or the like.

As the resin liquid in the above, for example, one or two thermosetting resins such as urea resin, melamine resin, acetoguanamine resin, benzoguanamine resin, unsaturated polyester resin, diallyl phthalate resin, or initial condensates thereof. A resin liquid containing the above as main components can be used.

In this case, the amount of resin attached to the impregnated paper is 5 in terms of solid content.
Although the object of the present invention can be achieved with a resin adhesion amount of 0 to 150%/m'', a resin adhesion amount of 60 to 80 (Ft) is preferably used.

In addition, the base material applicable to the present invention is plywood. The printing paper is dried at 120°C for 1 minute, the silicone ink on the conduit part is cured, and the solid content is 809/7r with the following resin mixture.
I impregnated.

(Resin formulation) The impregnating liquid impregnated with 188 parts of diallyl phthalate polymer was dried at 80° C. for 10 minutes to obtain impregnated paper.

Next, layer the impregnated paper on the plywood from step 3 with the ink side facing up,
A polished duralumin plate was placed thereon with the mirror surface facing downward, and pressed at 140° C. and 10 kfI/Cd for 8 minutes. After pressing, when the duralumin plate is released from the mold, the resin only in the conduit part has poor affinity with the ink layer forming the conduit part, and due to the hardening suppressing effect, the resin in this part is uncured and transfers to the duralumin plate. , a matching embossed decorative board with sharpness and depth was obtained.

[Example 2] A wood grain pattern was gravure printed on 809/ml titanium paper using ordinary gravure ink, and then a conduit portion was printed using a gravure printing machine using releasable ink.

(Ink formulation) Dry the printing paper at 200°C for 1 minute to harden the silicone ink on the conduit, and add the following resin formulation to a solid content of 80%.
9/A Impregnated.

(Resin formulation) The impregnated liquid was dried at 80°C for 10 minutes to obtain impregnated paper.

, Next, the impregnated paper was stacked on the plywood from step 3 with the ink side facing up, and a polished duralumin board was placed on top of it with the mirror surface facing downward, and pressed at 140°C and 10kg/C77i for 8 minutes. . When the duralumin plate is released from the mold after pressing, the resin only in the conduit part has poor affinity with the conduit part, and due to the hardening suppressing effect, the resin in this part is uncured and transfers to the duralumin plate, resulting in a sharp and deep layer. I got a matching embossed decorative board.

[Example 3] A wood grain pattern was gravure printed on a 559/I titanium paper using ordinary gravure ink, and then a conduit portion was printed using a gravure printing machine using the same ink as in Example 1, and then 1
Dry at 20°C for 1 minute to harden the ink on the conduit part, impregnate with the same impregnating resin liquid as in Example 1 at a solid content of 559/I, and dry the impregnated liquid at 80°C for 10 minutes to obtain impregnated paper. And so.

Below, under the same conditions as in Example 1, vinylon film was used, impregnated paper was placed on 4% plywood, heated and pressurized, and the vinylon film was released from the mold. The resin on the conduit was transferred to the vinylon film, and the recesses and patterns were formed. A completely synchronized embossed decorative board was obtained.

[Example 4] A wood grain pattern was gravure printed on 809/I titanium paper using a normal gravure ink, and a conduit portion was printed using a gravure printing machine using the following ink composition.

(Ink formulation) The printing paper was dried at 200° C. for 1 minute to cure, and then impregnated with a solid content of 969/7rI using a resin compounded plate.

(Resin formulation) Dry the impregnated liquid at 80°C for 10 minutes, stack the impregnated paper on a plywood board from 3 to 3 with the ink side facing up, and then place 2 on top of it.
It was placed so that the 0% matte surface was the bottom surface, and heated and pressurized under the same conditions as in Example 1.

Claims (1)

[Claims] 1 After providing a pattern on decorative paper with an ink containing a resin that has release properties for the thermosetting resin to be impregnated and a curing inhibitor for the thermosetting resin to be impregnated, the above-mentioned release resin is cured. Then, the entire surface of the decorative paper including the pattern is impregnated with a thermosetting resin and dried to produce an impregnated paper.Then, the impregnated paper is layered on a base material, and a molded plate or film is placed on top of it. After that, heat and pressure is applied to harden the thermosetting resin in the non-patterned area, and then the uncured resin on the pattern is adhered onto the molded plate or film, and the molded plate or film is peeled off using a trowel. A method for manufacturing a decorative board, characterized by forming recesses.